Mechanical Process & Manufacturing Specialist

Location: Bangalore - Indraprastha, India

Thales is a global technology leader trusted by governments, institutions, and enterprises to tackle their most demanding challenges. From quantum applications and artificial intelligence to cybersecurity and 6G innovation, our solutions empower critical decisions rooted in human intelligence. Operating at the forefront of aerospace and space, cybersecurity and digital identity, we’re driven by a mission to build a future we can all trust.

Present in India since 1953, Thales is headquartered in Noida and has other operational offices and sites spread across Delhi, Gurugram, Bengaluru and Mumbai, among others. Over 2200 employees are working with Thales and its joint ventures in India. Since the beginning, Thales has been playing an essential role in India’s growth story by sharing its technologies and expertise in Defence, Aerospace and Cyber & Digital sectors. Thales has two engineering competence centres in India - one in Noida focused on Cyber & Digital business, while the one in Bengaluru focuses on hardware, software and systems engineering capabilities for both the civil and defence sectors, serving global needs. The Group has also established an MRO (Maintenance, Repair & Overhaul) facility in Gurugram to provide comprehensive avionics maintenance and repair services to Indian airlines and support the growth of the local aviation industry.

Primary Purpose of the Role

Thales is expanding its presence in India through the development of a Group Engineering Competence Centre (ECC), reinforcing its position as a leader in all its markets. Launching in early 2019 in Bengaluru, the ECC will expand Thales’ footprint in its core business areas and cement its long-standing relationship with India. Thales has an objective to expand industrial process engineering function in India ensuring remote engineering support to Thales Industry and preparing industrial footprint expansion in the region. Achieving a high level of maturity for our products in production is one of the major challenges of the Thales industry, both during the industrialization phase and throughout the product's life cycle.

This Job Description is for Industrial Process Engineering & the Role is MECHANICAL PROCESS & MANUFACTURING SPECIALIST
The role is based in Bangalore and requires frequent travel to supplier sites across Bangalore and other locations within India and Asia.

Organization
You will be part of the Industrial Process Engineering – Industrialization team, responsible for defining and managing manufacturing technologies for electronic boards, mechanical components, and related processes. The team supports all product life-cycle phases, bidding, development, and series production. Key Responsibilities and Tasks
Core Responsibilities
•Responsible for co-developing, qualifying, optimizing, Mechanical Manufacturing & Assembly processes with Suppliers
•Work closely with suppliers to ensure adherence to approved manufacturing processes, specifications, and quality requirements - Serve as the primary technical point of contact for manufacturing processes with suppliers.
•Review, challenge, and validate supplier process documentation (process flows, control plans, PFMEA, work instructions) and ensure compliance with standards, customer, and internal guidelines.
•Support resolution of manufacturing and quality issues during development and series production, including participation in supplier audits and on-site technical reviews.
•Drive continuous improvement initiatives with suppliers, including cost, quality, lead-time optimization, supplier qualification, and standardization of best practices across the supply base.
•Manage process evolution and technology upgrades.

NPI Activities (working with industrial architects and engineering teams)
Support New Product Introduction (NPI) and industrialization activities at supplier sites in following phases:
•R& T Phase:
oCollaborate with R&T teams to support industrialization activities(POC, Mock up), Manufacturing Readiness Level (MRL) maturity plans, and the introduction of emerging mfg. technologies, materials, and processes.
•Bidding Phase:
oEvaluate and recommend manufacturing processes based on risk assessments and supplier capability, process maturity including technical support during supplier selection.
•Development Phase:
oDevelop, execute and approve process qualification and APQP plans to confirm manufacturing readiness, including tooling, materials, and equipment capability.
oConduct DFM/DFA reviews with internal design teams and suppliers and propose design optimizations to achieve target cost and manufacturability objectives.
oLead supplier industrial reviews such as Production Readiness Reviews (PRR) and First Article Inspections (FAI).
oSupport or lead run-at-supplier (pilot line / proto) trials to validate joining process feasibility.
oEnsure suppliers conduct proper capability studies (Cp, Cpk) & validate
oSupport supplier in implementing process monitoring systems (e.g., force-displacement curves, camera vision systems).
oAssist supplier in equipment selection and approval to ensure compliance with process performance targets.
oWork with suppliers to ensure tooling, jigs, and fixtures are robust and durable for operation.

Transfer & Series Production Activities (in coordination with Series Product Managers, Supplier Product Quality Managers, and Industrial Transfer Managers)
•Support BTP (Build To Print) transfer by ensuring the supplier achieve technical capability (mastering of technological processes before transfer)
•Provide technological support for production, including defect analysis and expert intervention.
•Lead root cause analysis and drive corrective actions for manufacturing or assembly issues.
•Manage risk assessments and mitigation strategies throughout the project lifecycle.
•Manage process evolution and technology upgrades with subcontractors and relevant stakeholders

Cross-Functional Missions
•Develop and update technical standards within the Mechanical domain; participate in Thales Group-wide working groups.
•Suggest process and business tool improvements to enhance efficiency and quality.
•Maintain adherence to aerospace quality standards, including ISO and EN 9100
Work closely with the France team to understand and benchmark processes, then collaborate with suppliers to implement and qualify those processes.

Major Challenges
• Ensure Supplier Quality Process Development meets global industrial plan & Timeline
• Work with multiple GBU’s/BL’s of France in a different Time Zone
• Work with multiple Suppliers/multiple projects in tandem for Process Qualification
• Continuously Develop the required technical skills (skilling-up) and capability by effective learning Opportunities
• Opportunity to work in an organization driving the development of a structured engineering footprint aligned with Thales’ growth and competitiveness ambitions.
• Opportunity to collaborate with colleagues from diverse cultural backgrounds across the globe
• A work environment that fosters professional development through continuous learning, close team collaboration, and a solution-oriented mindset. Skills & Knowledge Required Technology

Skills
• Strong Knowledge of precision mechanical manufacturing and assembly technologies:
o Mandatory – 5 Axis machining, Turning, Milling, Riveting, Clinching, Screwing, Press Fitting.
o Nice to Have – EDM, Heat treatment, Brazing, Gluing, Casting, Forging
• Nice to Have - Knowledge on Surface Treatment - Aluminum Corrosion protection, Chemical Conversion-Surtec, Anodization & Metal Plating (Ni, Silver, Zinc), Painting
• Knowledge of expertise techniques and methods: SEM, X-rays, micro-sectioning, destructive analyses
• Proficiency in reading engineering drawings, GD&T, and tolerance stack-up analysis
• Hands-on experience with process validation, SPC, and Measurement Tools usage
• Experience with lean manufacturing principles, including 5S, Kaizen, and value stream mapping.
• Competency in process optimization to improve cycle time, reduce waste, and enhance throughput.
• Knowledge of safety standards and ergonomics in manufacturing environments.

Software/Tools:
• CAD software (CREO, AutoCAD) Quality Tools
• Hands on of APQP (Advanced Product Quality Planning) methodology & documentation.
• Experienced in root cause analysis and problem-solving techniques (PDCA, 8D, 5 Whys, Fishbone)

Soft Skills
• Learning & Proactive mindset with a continuous focus on improvement.
• Strong analytical, communication, interpersonal and problem-solving abilities.
• Dynamic and flexible, able to adapt to changing priorities.
• Analytical thinker with strong problem-solving skills and logical reasoning.
• Detail-oriented with a focus on quality and continuous improvement.
• Ability to work independently and manage multiple priorities.

Years of experience Required
• 8 to 10 years of experience in precision part manufacturing and assembly, including NPI and series production in In House & outsourced environments.
• Experience in the aerospace sector is preferred.

Educational Qualification Required
• Bachelor/Masters in Mechanical Engineering

Language • English • French basic knowledge is a plus

At Thales, we’re committed to fostering a workplace where respect, trust, collaboration, and passion drive everything we do. Here, you’ll feel empowered to bring your best self, thrive in a supportive culture, and love the work you do. Join us, and be part of a team reimagining technology to create solutions that truly make a difference – for a safer, greener, and more inclusive world.